Kit for transforming a hot rod into an electric car

ABSTRACT

A combination for transforming a gasoline powered Chevrolet V8 engine into an electrically powered Chevrolet V8 engine is provided, the combination comprising: a faux transmission housing; a bell housing attached to a front end of the faux transmission housing; a faux engine attached to a front of the bell housing; and an electric motor, wherein the combination is free-standing and comprises a plurality of castings assembled to provide a faux transmission case in which the electric motor is housed, and a faux engine case configured to house a plurality of rechargeable batteries.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims benefit of Canadian Patent Application SerialNo. 3,060,096, filed on Oct. 23, 2019, entitled KIT FOR TRANSFORMING AHOT ROD INTO AN ELECTRIC CAR, the contents of which are incorporatedherein by reference.

FIELD

The present technology allows a user to transform a car with a V8 engineinto an electric car that retains the look of the V8 engine. Morespecifically, it is an easy to use kit comprising an electric motor anda case for housing the electric motor such that the car retains theappearance of the original car.

BACKGROUND

With the growing number of electric cars, hotrodders and car enthusiastshave begun to see the advantages of an electric motor driven vehicle.The older cars are very fuel inefficient, the engines are getting oldand more and more difficult to find parts for and the engines lack thetorque of an electric engine. Unfortunately, replacing the gas enginewith an electric motor destroys the look of the engine compartment. Manycar enthusiasts want to retain as much of the look of their oldervehicle as possible. There are examples of engine covers and replacementparts that can be used to change the look of a gas engine.

In a related art, United States Patent Application 20050132997 disclosesa customization cover for use with an engine valve cover that has a mainbody portion configured with one or more design elements thereon toprovide an improved visual effect for a vehicle engine and enginecompartment. Mounting openings in the main body member are cooperativelyconfigured to receive a connector element to place the customizationcover generally above the valve cover. Preferably, side componentshaving side design elements extend downwardly from the main body to froma generally elongated channel that is disposed above the valve cover.The connector elements can connect to the valve cover mounting points orto the ignition coil mounting points. Spacer elements, brackets and/ormounting arms on the side components can be utilized to secure thecustomization cover in a spaced apart relation to the valve cover toprovide an enhanced three-dimensional visual effect. This simply addsdecorative elements to the engine valve cover and does not shroud theengine. The result is not an engine that has the appearance of a V8engine.

United States Patent Application 20100269779 discloses a valve coverthat includes a base that attaches to an engine and a display windowthat attaches to the base. The display window is made of material thatcan withstand the operating environment of the engine, includingtemperature and resistance to petroleum-based substances. The displaywindow is secured to the base using a flexible gasket that encircles thedisplay window and snaps into a groove in the base to secure the displaywindow to the base. The display window may be see-through so the valvesare visible. The display window may also include one or more displayelements, such as light-emitting diodes, optical fibers,electro-luminescent panels, incandescent bulbs, liquid crystal displays,etc. The display window may include embossed or etched portions and mayinclude multiple colors and sequenced operation to provide any desiredeffect on the display panel. The result is not an engine that has theappearance of a V8 engine.

United States Patent Application 20060070599 discloses an engine coverincludes an installation member, a cover body, and an installed member.The installation member is disposed on an engine. One of theinstallation member and the installed member includes a leg, and a head,and the other one of them includes a framed member, and an elasticmember. The elastic member includes a first hole, a second hole, and adiametrically-enlarged intermediate hole. The head engages with thediametrically-enlarged intermediate hole. Moreover, the head is disposedmovably toward the second hole when a downward load is applied to thecover body, thereby bringing the cover body closer to the engine. Theresult is not an engine that has the appearance of a V8 engine.

U.S. Pat. No. 4,149,512 discloses an internal combustion engine having asound-deadening shroud surrounding the engine block and connected tolatter with the interposition of anti-vibration means. An exhaust plantthrough which combustion gases are connected is arranged external of theshroud and connected to the engine block. A separate enclosure issecured to the shroud and encloses the exhaust plant leaving a small airgap on all sides between the exhaust plant and the enclosure with onlythe exhaust pipe of the exhaust plant projecting from the enclosurethrough an opening. The result is not an engine that has the appearanceof a V8 engine.

Canadian Patent 2923368 discloses a kit for shrouding a stock gasolinepowered engine to make it appear as a flathead engine, the kitcomprising a timing cover casting, a front casting, a pair of exhaustmanifold panel castings, a pair of valve cover castings, a pair ofsupport bars, an intake manifold casting, a rear casting, andinstructions. Also provided are a method of manufacturing the kit, amethod of assembling the kit and a faux flathead engine. The designrelies on the large size of the small block engine. The result is not anengine that has the appearance of a V8 engine.

With the strong growth in electric cars, it is only a matter of timebefore hot rod enthusiasts will be using electric motors to power theirhot rods. None of the prior art addresses the need fora kit that allowssuch a transformation while retaining the look of the original engine.What is needed is a kit and product that provides a case or shroud foran electric motor that results in it appearing to be a V8, V12 or V16engine. The kit would preferably be easy to install and would encase theentire electric motor. It would be best if it could be installed in amatter of hours.

SUMMARY

The present technology provides an easy to assemble kit, or the alreadyassembled free-standing shroud for a stock electric motor that resultsin it appearing to be a V8 engine, more specifically a Chevrolet V8engine. The stock electric motor is housed in the cavity of the shroudand is completely concealed or is housed in the faux transmissionhousing. A large void volume in the cavity and numerous concealedopenings promotes air flow and thus cooling for the electric motor. Thekit can be assembled and installed in a matter of hours. The shroud canbe configured for a V12 or V16, by simply extending the side piece moldsfor the V8, whilst using the same molds for the remainder of the partsfor production. The product is a shroud and electric motor that mimics agasoline engine in exterior appearance. The shroud is light weight.

In one embodiment, a combination for transforming an internal-combustionvehicle into an electric vehicle, while retaining the physicalappearance of an internal-combustion vehicles is provided, thecombination comprising: a faux transmission housing; a bell housingattached to a front end of the faux transmission housing; a faux engineattached to a front of the bell housing; and an electric motor, whereinthe combination is free-standing and comprises a plurality of castingsassembled to provide a faux transmission case in which the electricmotor is housed, and a faux engine case configured to house a pluralityof rechargeable batteries.

In the combination, the faux transmission housing may be spaced apartfrom the electric motor to define a void volume surrounding the electricmotor.

In the combination, the internal-combustion vehicle is powered by aChevrolet V8 engine.

In the combination, the plurality of castings may include a timing covercasting, a back casting opposite the timing cover casting and a pair ofside castings disposed therebetween.

In the combination, the plurality of castings may include a pair of headcastings which are hollow, sit on top of the pair of side castings andextend between the timing cover casting and the back casting.

In the combination, the plurality of castings may include an intakemanifold casting, which sits between the pair of heads and extendsbetween the timing cover casting and the back casting.

The combination may further comprise a pair of stock valve covers whichare mounted on the pair of heads.

The combination may further comprise a microprocessor, themicroprocessor in electronic communication with the electric motor.

In the combination, the pair of side castings may mimic a lower side ofa block and the oil pan of the Chevrolet V8 engine.

In the combination, the pair of side castings may include a plurality ofapertures, the faux engine further comprising a plurality of pipesattached to and extending from the apertures to provide a fluidconnection between the case and the ambient environment.

The combination may further comprise the plurality of rechargeablebatteries.

The combination may further comprise: a battery case which is housed inthe faux engine; and fuses, which are housed in the battery case and arein electrical communication with the electric motor and the rechargeablebatteries.

In another embodiment, a kit for transforming an internal-combustionvehicle into an electric vehicle, while retaining the physicalappearance of an internal-combustion vehicles, the kit comprising: afaux transmission housing including a plurality of castings, which whenassembled provide a case for housing an electric motor; a bell housing;and a faux engine including a plurality of castings, which whenassembled provide a case for housing a plurality of rechargeablebatteries.

The kit may further comprise a battery case and a plurality of wires.

In the kit, the plurality of castings may include a timing covercasting, a back casting and a pair of side castings.

In the kit, the plurality of castings may include a pair of headcastings which are hollow.

In the kit, the plurality of castings may include an intake manifoldcasting.

The kit may further comprise a pair of stock valve covers.

The kit may further comprise the electric motor.

The kit may further comprise a microprocessor.

In the kit, the internal-combustion vehicle is powered by a Chevrolet V8engine.

In one embodiment, a faux engine is provided, the faux engine comprisingan electric motor, a transmission in motive communication with theelectric motor, a transmission housing surrounding the transmission anda free-standing case for the electric motor, wherein the case comprisesa plurality of castings assembled to provide a cavity to house theelectric motor, is configured to conceal the electric motor and mimic anexterior of a V8 engine.

In the faux engine, the case may be spaced apart from the electric motorto define a void volume surrounding the electric motor.

In the faux engine, the plurality of castings may include a timing covercasting, a back casting opposite the timing cover casting and a pair ofside castings disposed therebetween.

In the faux engine, the plurality of castings may include a pair of headcastings which are hollow, sit on top of the pair of side castings andextend between the timing cover casting and the back casting.

In the faux engine, the plurality of castings may include an intakemanifold casting, which sits between the pair of heads and extendsbetween the timing cover casting and the back casting.

The faux engine may further comprise a pair of stock valve covers whichare mounted on the pair of heads.

In the faux engine, the plurality of castings may be aluminum castingsthat are welded to one another.

The faux engine may further comprise a microprocessor, themicroprocessor in electronic communication with the electric motor andthe transmission.

In the faux engine, the pair of side castings may mimic a lower side ofa block and the oil pan of the V8 engine.

In the faux engine, the pair of side casting may define an openingbetween the cavity and an ambient environment.

In the faux engine, the pair of side castings may include a plurality ofapertures, the faux engine further comprising a plurality of pipesattached to and extending from the apertures to provide a fluidconnection between the cavity and the ambient environment.

In another embodiment, a free-standing V8 shroud for an electric motoris provided, the free-standing V8 shroud comprising a plurality ofcastings assembled to provide a cavity, the cavity for housing theelectric motor, and an exterior, the exterior configured to mimic anexterior of a CV8 engine, and to conceal the electric motor.

In the free-standing V8 shroud, the plurality of castings may include atiming cover casting, a back casting opposite the timing cover castingand a pair of side castings disposed therebetween.

In the free-standing V8 shroud, the pair of side castings may mimic alower side of a block and the oil pan of the V8 engine.

In the free-standing V8 shroud, the pair of side casting may define anopening between the cavity and an ambient environment.

In the free-standing V8 shroud, the pair of side castings may include aplurality of apertures, the free-standing V8 shroud further comprising aplurality of pipes attached to and extending from the apertures toprovide a fluid connection between the cavity and the ambientenvironment.

The free-standing V8 shroud may further comprise a pair of stock valvecovers which are mounted on the pair of heads.

In the free-standing V8 shroud, the plurality of castings may include apair of head castings which are hollow, sit on top of the pair of sidecastings and extend between the timing cover casting and the backcasting.

In another embodiment, a kit for changing a V8 engine to an electricmotor is provided, the kit comprising an electric motor and a case forthe electric motor, the case comprising a plurality of castings whichwhen assembled provide a cavity, the cavity for housing the electricmotor, and an exterior, the exterior configured to mimic an exterior ofthe V8 engine, and to conceal the electric motor.

In the kit, the plurality of castings may include a timing covercasting, a back casting and a pair of side castings.

In the kit, the pair of side castings may mimic a lower side of a blockand the oil pan of the V8 engine.

FIGURES

FIG. 1 is a perspective view of a prior art V8 engine.

FIG. 2 is a perspective view of the assembled shroud of the presenttechnology.

FIG. 3 is an exploded view of the shroud of the present technology.

FIG. 4A is a perspective view of an alternative embodiment of the shroudof FIG. 1 ; FIG. 4B is a perspective view of another alternativeembodiment of the shroud of FIG. 1 ; and FIG. 4C is a perspective viewof yet another alternative embodiment of the shroud of FIG. 2 .

FIG. 5 is a perspective view of another alternative embodiment of theshroud of FIG. 2 .

FIG. 6 is a longitudinal sectional view of the shroud of the presenttechnology.

FIG. 7 is a cross sectional view of the shroud of the present technologythrough line 6 in FIG. 6 .

FIG. 8 is a schematic of a side view of the faux engine of the presenttechnology further comprising a microprocessor.

FIG. 9 is a longitudinal sectional view through an alternativeembodiment of FIG. 6 .

FIG. 10 is a top view of the engine compartment.

FIG. 11 is a perspective view of the alternative embodiment.

DETAILED DESCRIPTION

Except as otherwise expressly provided, the following rules ofinterpretation apply to this specification (written description andclaims): (a) all words used herein shall be construed to be of suchgender or number (singular or plural) as the circumstances require; (b)the singular terms “a”, “an”, and “the”, as used in the specificationand the appended claims include plural references unless the contextclearly dictates otherwise; (c) the antecedent term “about” applied to arecited range or value denotes an approximation within the deviation inthe range or value known or expected in the art from the measurementsmethod; (d) the words “herein”, “hereby”, “hereof”, “hereto”,“hereinbefore”, and “hereinafter”, and words of similar import, refer tothis specification in its entirety and not to any particular paragraph,claim or other subdivision, unless otherwise specified; (e) descriptiveheadings are for convenience only and shall not control or affect themeaning or construction of any part of the specification; and (f) “or”and “any” are not exclusive and “include” and “including” are notlimiting. Further, the terms “comprising,” “having,” “including,” and“containing” are to be construed as open-ended terms (i.e., meaning“including, but not limited to,”) unless otherwise noted.

Recitation of ranges of values herein are merely intended to serve as ashorthand method of referring individually to each separate valuefalling within the range, unless otherwise indicated herein, and eachseparate value is incorporated into the specification as if it wereindividually recited herein. Where a specific range of values isprovided, it is understood that each intervening value, to the tenth ofthe unit of the lower limit unless the context clearly dictatesotherwise, between the upper and lower limit of that range and any otherstated or intervening value in that stated range, is included therein.All smaller sub ranges are also included. The upper and lower limits ofthese smaller ranges are also included therein, subject to anyspecifically excluded limit in the stated range.

Unless defined otherwise, all technical and scientific terms used hereinhave the same meaning as commonly understood by one of ordinary skill inthe relevant art. Although any methods and materials similar orequivalent to those described herein can also be used, the acceptablemethods and materials are now described.

Definitions

Stock electric engine: In the context of the present technology, a stockelectric engine is the engine that is used to run the vehicle and ismade to look like a gasoline engine with the shroud. This could be, forexample, but not limited to, one or two electric motors.

Short block: A short block is the engine block.

Long block: A long block is the engine block and the two heads.

Gasoline engine: A gasoline engine is a long block with an intakemanifold, two valve covers and an oil pan.

A prior art V8 engine, generally referred to as 1 is shown in FIG. 1 .The block 2 includes upper sides 3 and lower sides 4. An oil pan 5 isattached to the bottom 6 of the block 2. A pair of heads 7 is attachedto the upper sides 3. An intake manifold 8 is attached to the top 9 ofthe block 2. The front and the back have their profile defined by theshape of the block 2 as shown.

An engine shroud, generally referred to as 10 is shown in FIG. 2 . Theshroud 10 is comprised of between three and seven, generally foursections of cast aluminum that, when assembled, mimics the look of aChevrolet V8 engine. A timing cover casting 12, a right side casting 14,a right side head casting 16 and an intake manifold casting 18 can beseen. In all embodiments, the valve covers 19 are stock, as they arelight weight components.

In another embodiment, the shroud mimics the look of a Ford V8 engine.

As shown in FIG. 3 , there are two side castings, the right side casting14 and a left side casting 20. The right and left side castings 14, 20mimic both the oil pan and the lower sides of the block of a V8 engine.The back casting 22 includes an aperture 24 and four motor mounts 26extending outward from the aperture 24 as four raised bars. The profileof the back casting 22 is the same as the profile of the back of thestock V8 block 1. Bolts 28 bolt the back casting 22 to the transmissioncasing of the car. The timing cover casting 12 mimics the timing coverof a V8 engine. It has the same profile as the front of the stock V8block 1. In order to save weight and to promote heat transfer from theelectric motor to the ambient, the right head and the left head of theV8 engine are mimicked with a right head casting 16 and a left headcasting 32. The head castings 16, 32 include four exhaust apertures 34each. The head castings 16, 18 are hollow so as to promote cooling andair flow, as well as to reduce weight. In one embodiment, the exhaustapertures 34 are fitted with short exhaust pipes 36. Cooling air entersinto the motor cavity 38 (see FIG. 6 ) through the pipes 36 and theexhaust apertures 34. The intake manifold casting 18 also saves weightand promotes heat transfer from the motor cavity 38.

In another embodiment shown in FIG. 4A, stock right 40 and left exhaustmanifolds 42 (not shown) are attached to the right and left headcastings 16, 32 (not shown). In this embodiment, the intake manifoldcasting 18 is replaced with a stock intake manifold 44 to provide a fauxengine.

In another embodiment shown in FIG. 4B, short exhaust pipes 36 areattached to the right and left head castings 16, 32 and the intakemanifold casting 18 is replaced with the stock intake manifold 44. Inyet another embodiment shown in FIG. 4C, the stock right 40 and leftexhaust manifolds 42 (not shown) are attached to the right and left headcastings 16, 32 (not shown) and the intake manifold casting 18 replacesthe stock intake manifold 44 to provide a faux engine.

In another embodiment shown in FIG. 5 , a single casting, generallyreferred to as 100 is cast in aluminum. It includes the right sidecasting 14, the left side casting 20, timing cover 12 and back 22 of theembodiment described in relation to FIG. 3 . This is a short block.Additional castings may include the right head casting 16, the left headcasting 32 (to provide a long block) and the intake manifold casting 18,or the stock parts may be used as described in relation to FIG. 4A-C.

As shown in FIG. 6 , the electric motor 50 sits in the motor cavity 38and is surrounded by air (there is a void volume surrounding theelectric motor 10, or in other words, the case 10 and the electric motor50 are spaced apart from one another, leaving an air gap between theelectric motor and the case 10—the case 10 does not touch or sit uponthe electric motor 50).

The castings are welded to one another, with the timing cover casting 12and the back casting 22 both welded to the side castings 14, 20, theright head casting 16 welded to the right side casting 14, the timingcover casting 12 and the back casting 22, the left head casting 32welded to the left side casting 20, the timing cover casting 12 and theback casting 22, the intake manifold casting 18 welded to the timingcover casting 12, the back casting 22 and the right and left headcastings 16, 32.

As shown in FIG. 7 , the side castings 14, 20 terminate in a loweropening 60. As this is well below the electric motor 50, the electricmotor 50 is totally concealed from a viewer, once the shroud 10 andelectric motor 50 are mounted in the engine compartment of the nowelectric car. The lower opening 60 provides further ventilation andcooling for the electric motor 50.

As shown in FIG. 8 , the electric motor 50 is in motive communicationwith the transmission via the rear shaft 52, which is preferably amanual transmission. The front shaft 54 runs the same pulley that thestock V8. This pulley allows for the alternator, power steering, waterpump and air conditioning, as included, to run. Wires 56 provideelectrical connections between the electric motor 50 and the battery orbatteries. The batteries are preferably stored in the trunk or rear ofthe vehicle.

In one embodiment, the electric motor 50 and the batteries are undercontrol of a microcontroller 60. The microcontroller 60 is in electroniccommunication with the transmission, the electric motor 50 and theengine peripherals (alternator, power steering, water pump and airconditioning). The microcontroller 60 is housed in a housing 62 whichincludes a channel 64 and a cooling plate 66. Water from the water pumpcirculates through the channel 64 and cools the plate 66, thus keepingthe microcontroller 60 cool.

In another embodiment shown in FIG. 9 , the electric motor 50 is housedin a faux transmission housing 70, which defines a case 72 and is behindthe bell housing 74. The electric motor 50 is surrounded by air (thereis a void volume surrounding the electric motor 10, or in other words,the housing 70 and the electric motor 50 are spaced apart from oneanother, leaving an air gap between the electric motor 50 and thehousing 70—the faux transmission housing 70 does not touch or sit uponthe electric motor 50). The front shaft 54 is rotatably mounted on aplate 76 which in turn is mounted on the bell housing 74. The rear shaft52 extends through the back 78 to a gear reduction box 80, which ispreferably a Torque Trends gear reduction box.

In an alternative embodiment, the gear reduction box 80 is housed withinthe faux transmission housing 70 and the rear shaft 52 does not extendthrough the back 78. A motor microcontroller 84 is mounted in the fauxtransmission housing 70 and is in electronic communication with theelectric motor 50. A water pump 86 is also mounted in the fauxtransmission housing 70. Water lines 88 extend between it and theradiator 90 for cooling the electric motor 50. A battery managementsystem 60 is housed in the housing 62 in the motor case 38. The housing62 includes a channel 64 and a cooling plate 66. Water from the waterpump circulates through the channel 64 and cools the plate 66, thuskeeping the battery management system 60 cool. In an alternativeembodiment, the battery management system is cooled with a heatexchanger, which includes a fan. A preferred battery management systemis the OrionBMNS. Rechargeable batteries 92, which are preferablylithium-ion batteries, are housed in the engine shroud 10 and sit on thebase 94 of the engine shroud 10. The rechargeable batteries 92 power theelectric motor 50.

As shown in FIG. 10 , a pseudo battery 74 houses fuses which are inelectrical communication with the electric motor 50 and rechargeablebatteries 92. The pseudo battery 74 is a battery case. The wire leads 76extend from the pseudo battery 74 to the electric engine 50 via thebattery terminals on the pseudo battery 74. The engine shroud 10 and thepseudo battery 74 are retained in the engine compartment 38.

As shown in FIG. 11 , the engine shroud 10 with the engine 50 housed inthe faux transmission housing 70 mimics the look of a Chevrolet V8engine, bell housing and transmission, thus there is a faux engine andfaux transmission. The intake manifold casting 18, the left head casting32 and the left side casting 20 can be seen. The side castings 14, 20extend back and form part of the faux transmission housing 70. In oneembodiment the faux transmission housing 70 may be cast as two castings.In another embodiment the faux transmission housing is a back casting100 and a shaped aluminum sheet cover 102. The valve covers 19 arestock, as they are light weight components.

While example embodiments have been described in connection with what ispresently considered to be an example of a possible most practicaland/or suitable embodiment, it is to be understood that the descriptionsare not to be limited to the disclosed embodiments, but on the contrary,is intended to cover various modifications and equivalent arrangementsincluded within the spirit and scope of the example embodiment. Thoseskilled in the art will recognize or be able to ascertain using no morethan routine experimentation, many equivalents to the specific exampleembodiments specifically described herein. Such equivalents are intendedto be encompassed in the scope of the claims, if appended hereto orsubsequently filed.

The invention claimed is:
 1. A combination for transforming aninternal-combustion vehicle into an electric vehicle, while retainingthe physical appearance of the internal-combustion vehicle, thecombination comprising: a faux transmission housing; a bell housingattached to a front end of the faux transmission housing; a faux engineattached to a front of the bell housing; and an electric motor, whereinthe combination is free-standing and comprises a plurality of castingsassembled to provide a faux transmission case in which the electricmotor is housed, and a faux engine case configured to house a pluralityof rechargeable batteries.
 2. The combination of claim 1, wherein thefaux transmission housing is spaced apart from the electric motor todefine a void volume surrounding the electric motor.
 3. The combinationof claim 2, wherein the plurality of castings includes a timing covercasting, a back casting opposite the timing cover casting and a pair ofside castings disposed therebetween.
 4. The combination of claim 3,wherein the plurality of castings includes a pair of head castings whichare hollow, sit on top of the pair of side castings and extend betweenthe timing cover casting and the back casting.
 5. The combination ofclaim 4, wherein the plurality of castings includes an intake manifoldcasting, which sits between the pair of heads and extends between thetiming cover casting and the back casting.
 6. The combination of claim5, further comprising a pair of stock valve covers which are mounted onthe pair of heads.
 7. The combination of claim 6, further comprising amicroprocessor, the microprocessor in electronic communication with theelectric motor.
 8. The combination of claim 7 wherein the pair of sidecastings include a plurality of apertures, the faux engine furthercomprising a plurality of pipes attached to and extending from theapertures to provide a fluid connection between the case and the ambientenvironment.
 9. The combination of claim 8, further comprising theplurality of rechargeable batteries.
 10. The combination of claim 9,further comprising: a battery case which is housed in the faux engine;and fuses, which are housed in the battery case and are in electricalcommunication with the electric motor and the rechargeable batteries.